DEVICE FOR A SECURE DATA CONNECTION OF AT LEAST ONE MANUFACTURING MACHINE
The invention relates to a device for a secure data connection of at least one manufacturing machine (104), having an information-processing system (114), which is subdivided into individual zones (108, 110, 112) interconnected by data diodes (120) such that data originating from the machine control (118) of the manufacturing machine (104) in a data flow can be transferred to other zones (108, 110, 112) without the possibility of a data return flow, wherein said zones (110, 112), ordered hierarchically, each have a lower level of data security than the upstream zone (108, 110) in relation the data flow, and in that every zone (108, 110, 112) is formed as an independent computer in the manner of an isolated application. In addition, the invention relates to a manufacturing machine and a production plant.
The invention relates to a device for a secure data connection of at least one manufacturing machine and a manufacturing machine having such a device and a production plant having several such manufacturing machines.
In production companies, manufacturing machines are regularly integrated into an operational process based on the “automation pyramid” known from the state of the art, which is subdivided into different levels and which permits information to be transferred only in the vertical direction of its levels, wherein any information exchanged with external service providers happens via the highest level of the pyramid, i.e. at the enterprise resource planning (ERP) level. As a part of “Industry 4.0”, however, a direct connection of manufacturing machines to external data processing devices, such as computers of a cloud (cloud computing) or, with regard to the company operating the machine, to computers of other companies, is increasingly desired at the individual levels of the automation pyramid in the horizontal direction, without including further levels of the pyramid. However, in the case of such a direct connection of a manufacturing machine to an external data processing facility, means must be provided to protect the manufacturing machine from access by third parties.
From US 2015/0106912 A1 a device for a secure data connection of at least one manufacturing machine to an external (with respect to the manufacturing machine and with respect to the company operating the manufacturing machine) data server is known, having a controller formed as an integral component of the manufacturing machine, wherein on said controller software for data processing of the machine data of the manufacturing machine, in particular for buffering, forwarding and/or compression, is implemented, and wherein said controller is connected via an external (with respect to the manufacturing machine) firewall to a machine network, in which a plurality of manufacturing machines are provided, wherein said machine network via a further external (with respect to the relevant manufacturing machine) firewall is connected to the external data server, which is connected to the Internet.
Access control to the controller of the manufacturing machine, for the remote servicing for troubleshooting by an expert via the Internet, in one exemplary embodiment is implemented by an encryption and in a further exemplary embodiment by an upload of the machine data from the controller, without any data backflow, solely in the direction of the expert's company-external computer, wherein the upload of data denotes the transfer of data from a local computer or storage medium to a computer or storage medium remote from the local computer or storage medium.
An alteration affecting the machine control, such as a write access to the controller of the manufacturing machine, originating from an external (with respect to the manufacturing machine and/or to the company operating the machine) computer, wherein said alteration may have adverse effects on the product manufactured by the machine, cannot be completely ruled out by the known solution, e.g. because of a security gap, a software or hardware error (Spectre and Meltdown) and/or a flawed configuration of the firewalls.
Starting from this prior art, the invention addresses the problem of further improving the known solution such that the operational safety of the manufacturing machine is increased.
This problem is solved by a device for a secure data connection of at least one manufacturing machine, according to the invention, having the features of patent claim 1.
According to claim 1, the device according to the invention has a system that is subdivided into individual zones interconnected by data diodes such that data originating from the machine control of the manufacturing machine in a data flow can be transferred to other zones without the possibility of data backflowing, wherein said zones, ordered hierarchically, each have a lower level of data security than the upstream zone with respect to the data flow, and that every zone is formed as an independent computer in the manner of an isolated application.
The design of every zone in the manner of an island solution as an independent computer is defined as every computer being independently functional with regard to its hardware and software and being formed to be separate from the other computers at the hardware and software level, in particular spaced apart.
The information processing system is divided into zones, each of which is formed as an independently functioning computer in terms of software and hardware. By separating the zones at the software and hardware levels, an extremely effective access control can be set up in terms of security for read and/or write access of external (with regard to the manufacturing machine) data processing devices to the data originating from the machine control of the manufacturing machine.
In concrete terms, different zones of the information processing system having different levels of data security, i.e. data criticality, can be defined, which can be used to grant access rights in the form of either read and write access or read-only access to an individual external (with respect to the manufacturing machine) data processing device, in accordance with the data security of the individual zone connected to the data processing device. Thus, in the case of access of a data processing device to the zone having the highest level of data security, the data originating from the machine control of the manufacturing machine can be both changed in the sense of a write access and readable, and in the case of access to a zone having lower level of data security in relation to this zone, because of data transmission without any data return flow, i.e. unidirectional data transmission, from the zone having the highest level of data security in the direction of the zone having lower level of data security in relation thereto, the data can be read only and cannot be changed in the sense of a write access, i.e. is immutable by means of a write access.
As a result, a respective zone, subordinate to the zone having the highest level of data security and having a lower level of data security in relation to the latter, can be connected to an external data processing device without the possibility of write access to the data of the zone having the highest level of data security, originating from the machine control of the manufacturing machine. This increases the operational reliability of the manufacturing machine.
In a preferred exemplary embodiment, the first zone downstream of the machine control can, as the production zone, process at least machine data of the manufacturing machine and forward them to a monitoring zone and/or a service zone as the respective downstream zone, wherein said machine data can be forwarded to an company-internal or external network, such as the Internet. In this case, the respective network is formed as an company-internal or a (company-)external network, with regard to the company operating the manufacturing machine.
By data transmission can the production zone of the one machine control is connected to machine controls of other manufacturing machines within a production plant.
The production zone permits at least one of the data processing operations listed below: Data processing of data of the manufacturing execution system (MES) of a manufacturing management system and/or data processing of data collected over a period of time, and/or generation of production logs and/or reports. The MES is a process-related level of a manufacturing management system or production control system that can be represented schematically by the automation pyramid known from the state of the art. Here, the production management system or production control system is based on the product produced by the manufacturing machine.
The monitoring zone may permit at least one of the data processing operations listed below: Generating a data overview of a manufacturing machine, and/or detecting trends, and/or recording the operating state of the machine.
The service zone may permit at least one of the data processing operations listed below: Data processing of maintenance data, and/or recording the machine operating state, and/or performing remote diagnostics.
Data transmission between the individual manufacturing machines of a production plant can at least permit the transmission of the data listed below: Data of the Manufacturing Execution System (MES) of the manufacturing management system, and/or data collected over a period of time.
The company-internal network may at least permit the transmission of the data listed below: Data to generate an overview of multiple manufacturing machines, and/or data of mobile devices.
The external network can, preferably involving the cloud, at least permits the transmission of data for maintenance scheduling, and/or a creation of directories and/or documentation records and/or a link between real machine data and documentation in the cloud. This applies in particular to services offered by the machine manufacturer. Further applications are e.g. machine monitoring or predictive maintenance.
The respective data diode used between the individual zones having their computer units can be formed by a laser diode, which is used for light generation, and a photo diode, which is used for light detection of the generated light.
The zones, at least partially interconnected in parallel, can be connected in series with the first zone with respect to the data flow, and/or can be at least partially connected in series, starting from the first zone.
Every zone can comprise on the input end at least one protocol converter for protocol conversion and coupling of a data transfer protocol that can be transmitted by means of the data diodes to a data transfer protocol that can be processed by the zones and/or can comprise on the output end at least one further protocol converter for protocol conversion and coupling of a data transfer protocol that can be processed by the zones to a data transfer protocol that can be transmitted by means of the data diodes.
The computers can be formed identically, in particular with regard to their hardware and/or operating software, and can be configured for their intended use, in particular by means of application software, in accordance with the individual zone.
A data diode may be formed by a transmitting unit, which is part of a respective zone, and a receiver unit, which is part of a zone having a lower level of data security in relation to that zone, wherein a data transmission means is used to interconnect the transmitting unit and the receiver unit.
The transmitting unit may be formed as a transmitting data diode comprising a laser diode and, in particular, a multiplexer and a modulator, wherein the receiver unit may be formed as a receiving data diode comprising a photo diode and, in particular, a demodulator and a demultiplexer, and wherein the transmitting unit and the receiver unit are interconnected via the data transmission means in the form of an optical fiber cable.
According to claim 16, the subject matter of the invention is also a manufacturing machine having, as an integral part thereof, a device according to any one of the preceding claims. The solution according to the invention is particularly suitable for use in blow molding, filling and sealing machines. These are regularly used in the chemical-pharmaceutical and food industries.
According to claim 17, the subject matter of the invention is also a production plant comprising a plurality of manufacturing machines according to claim 16.
The device according to the invention can be used to particular advantage in companies in which a manufacturing machine must meet above-average safety requirements due to mandatory official regulations.
In such a case, for any change affecting the machine, a producer operating the manufacturing machine has to demonstrate that a particular change affecting the machine will not have any adverse effects on the product produced by the machine. Such a change can be, for instance, a connection of the machine to an external data processing device or an installation of an application software on the controller, i.e. the industrial control system, of the machine.
In addition, on the basis of the regulatory requirements the software services running on the controller of the machine, i.e. the various types of application software, depending on whether they relate to components and processes of the machine that have to be validated or are validated or do not have to be validated, are classified as Good Manufacturing Practice (GMP)-relevant software services subject to regulatory requirements or as non-GMP-relevant software services hardly subject to regulatory requirements, wherein write access by non-GMP-relevant software services to validated components or processes of the machine must be precluded mandatorily.
Therefore, in such “regulated companies”, after any such alteration the components and processes of the machine affected by these changes have to be validated based on test procedures and risk assessments, which is time-consuming and costly. However, even such test procedures or risk assessments cannot completely rule out adverse effects on the product manufactured by the machine because of access to the controller of the manufacturing machine from an external (with regard to the manufacturing machine) data processing device or because of newly installed application software.
Based on the design of the device according to the invention validation processes in the form of risk assessments and/or test procedures are at least partially eliminated, because the zone subordinate to the zone having the highest level of data security and having a lower level of data security in relation to it, can be connected to an external data processing device, without the possibility of write access to the data, originating from the machine control of the manufacturing machine, of the zone having the highest level of data security, and because the GMP-relevant application software can run in a zone having a higher level of data security and the non-GMP-relevant application software can run in a zone having a lower level of data security.
As a result, when the device according to the invention is used in combination with a manufacturing machine subject to official regulations, modifications affecting the manufacturing machine can be performed simply and inexpensively, in particular with regard to the connection of the manufacturing machine to external data processing equipment and/or the implementation of application software for the manufacturing machine, while complying with the relevant official safety requirements.
Below, the device, according to the invention, for the secure data connection of at least one manufacturing machine is explained in more detail with reference to the drawing. In the figures, in general view, not to scale,
Access control to the controller 10 of the manufacturing machine 4 for performing the remote service is implemented by encrypting or uploading the machine data from the controller 10 solely towards the company-external computer of the expert, without any data backflow.
The device according to the invention has an information-processing system 114 divided into three individual zones 108, 110, 112 (
A first zone 108 (
Every zone 108, 110, in particular a transmitting unit 128 (
The multiplexer 130 is provided by the layer 2a in the form of the MAC (Media Access Control) layer according to the 051 model (Open System Interconnection Model) known from the prior art, wherein said layer may additionally comprise a data flow control system and is part of the layer 2 in the form of the data link layer according to the 051 model. The multiplexer 130 can be used to transmit the data, provided by the protocol converters 126, in the form of corresponding different data streams via a single channel in the form of the data diode 120. The modulator 132 is provided by the layer 1 in the form of the physical layer according to the 051 model and is used to encode the data present digitally in the zones 108, 110 having the higher level of data security, into modulated analog data that can be transmitted using the data diode 120. The laser diode is part of an Ethernet transceiver, e.g. SFP (Small Form-Factor Pluggable) or SFP+, which is used as an optical fiber network interface and whose data receiving port Rx is blocked.
The zone 110, 112 having the lower level of data security (
The photo diode 142 is part of an Ethernet transceiver (e.g. SFP or SFP+) that serves as an optical fiber network interface and whose data transmitting port Tx is blocked. The demodulator 144 is provided by the physical layer according to the OSI model and is used to decode the modulated analog data that can be transmitted by the data diode 120 into digital data that can be processed by the zone 110, 112 having the lower level of data security. The demultiplexer 146 is provided by the MAC layer according to the 051 model and is used to separate the data streams combined by the multiplexer 130 of the transmitting unit 128.
In
The MES interface 148 of the production zone 108 (
The monitoring zone 110 (
Using the data summary 160, the efficiency of the manufacturing machine 104 can be monitored and less efficient components can be identified. In addition, a particularly good overview of the manufacturing machine 104 can be obtained by means of the data overview 160 when the key performance indicators are displayed. The browser of the terminal devices 162 can be used to access the data overview 160.
The service zone 112 (
Example applications of the device according to the invention and its advantages are discussed in more detail below:
Remote diagnosis: By introducing a service zone 112, the machine manufacturer 172 can provide remote diagnostics 180, which does not impose any additional risk or validation burden on the producer. In this case, access by the manufacturer 172 is limited to a subset of the data from the service zone 112 by means of the data filter.
Machine optimization: By introducing a service zone 112 in the manufacturing machine 104, usage data of the machine 104 can be recorded and transmitted to the machine manufacturer 172. These data can be used as a basis for further developments and improvements of the machine manufacturer 172. It can be used to better adapt future machine generations to the actual usage behavior of customers.
Efficiency Data Record: The formation of different zones 108, 110, 112 permits the efficiency data to be made available on the office network 158 or a cloud service. The recording of efficiency data of production lines and machines 104, e.g. Overall Equipment Effectiveness (OEE), permits the producer to evaluate process changes and identify improvement potentials. In particular, the recording of key figures is not necessarily GMP-relevant. Thus, the key figure recording does not require write access to the production zone 108, but only to the relevant information. In this respect, the key figures can be acquired and evaluated in a separate zone 110, 112.
Scheduling maintenance: Setting up of different zones 108, 110, 112 permits runtime information to be provided, improving the scheduling of maintenance work. For instance, the scheduling of maintenance activities on a manufacturing machine 104 ideally requires data on the operating time or cycles of operation of individual components or assemblies, e.g. a valve has to be replaced after a certain number of switching cycles or a seal after a certain number of operating hours. On the one hand, the machine manufacturer 172 can use runtime information to prepare deliveries of spare parts even before the producer orders them or to inform the producer about upcoming maintenance work; on the other hand, the producer can use such information to arrange a more efficient maintenance schedule.
Predictive Maintenance: The data-supported analysis of machine data, e.g. the switching time of valves, based on different zones 108, 110, 112 can be used to estimate when a component has to be replaced. For this purpose, the device permits local processing in a non-production zone, i.e., the monitoring zone 110 or the service zone 112. Additionally, the corresponding application software 122, 124 (
Pre-validation of application software: Because of the different zones 108, 110, 112 newly installed application software 122, 124 (
Production logs: The different zones 108, 110, 112 can be used to generate logs 174 (
GMP Documentation: By separating the GMP-relevant and the non-GMP-relevant software 122, 124 into different zones 108, 110, 112, the scope of the required GMP documentation can be reduced to the GMP-relevant software 122, 124 in the production zone 108.
Secure connection of alarms via insecure networks 166: The device permits alarms, status messages and other information to be sent directly to end devices 162, such as tablets, laptops and/or smartphones, via, in particular, insecure networks 166, such as the Internet and/or mobile networks, without any security risk to the producer.
Claims
1. A device for a secure data connection of at least one manufacturing machine (104), having an information-processing system (114), which is subdivided into individual zones (108, 110, 112) interconnected by data diodes (120) such that data originating from the machine control (118) of the manufacturing machine (104) in a data flow can be transferred to other zones (108, 110, 112) without the possibility of a data return flow, wherein said zones (110, 112), ordered hierarchically, each have a lower level of data security than the upstream zone (108, 110) in relation to the data flow, and in that every zone (108, 110, 112) is formed as an independent computer in the manner of an isolated application.
2. The device according to claim 1, characterized in that the first zone (108) downstream of the machine control (118), as a production zone, processes at least machine data of the manufacturing machine (104) and forwards them to a monitoring zone (110) and/or a service zone (112) as the respective downstream zone, wherein said machine data can be forwarded to an company-internal (150, 158) or external network (166), such as the Internet.
3. The device according to claim 1, characterized in that by data transmission (116) the production zone (108) of the one machine control (118) is connected to machine controls of other manufacturing machines within a production plant.
4. The device according to claim 1, characterized in that the production zone (108) permits at least one of the data processing operations listed below:
- data processing of data (152) of the manufacturing execution system of a manufacturing management system,
- data processing of data (156) collected over a period of time,
- generation of production logs (174) and/or reports (174).
5. The device according to claim 1, characterized in that the monitoring zone (110) permits at least one of the data processing operations listed below:
- generating a data overview (160) of a manufacturing machine (104),
- detecting trends (178),
- recording of the operating state (176) of the machine.
6. The device according to claim 1, characterized in that the service zone (112) permits at least one of the data processing operations listed below:
- data processing of maintenance data,
- recording the machine operating state (176),
- performing remote diagnostics (180).
7. The device according to claim 1, characterized in that the data transmission between the individual manufacturing machines of a production plant permits at least the transmission of the data listed below:
- data of the manufacturing execution system (152) of a manufacturing management system,
- data (156) collected over a period of time.
8. The device according to claim 1, characterized in that the company-internal network (158) permits at least the transmission of the data listed below:
- data to generate a data summary (164) of multiple manufacturing machines (104), mobile device data (162).
9. The device according to claim 1, characterized in that the external network (166), preferably including the cloud, permits at least the transmission of data for
- maintenance scheduling and/or
- a creation of directories (168) and/or documentation documents (168) and/or
- a link between real machine data and documentation in the cloud.
10. The device according to claim 1, characterized in that the respective data diode (120) used between the individual zones (108, 110, 112) having their computer units is formed by a laser diode (134), which is used for light generation, and a photo diode (142), which is used for light detection of the generated light.
11. The device according to claim 1, characterized in that the zones (110, 112) at least partially interconnected in parallel, are connected in series with the first zone (108) with respect to the data flow, and/or are at least partially connected in series, starting from the first zone (108).
12. The device according to claim 1, characterized in that every zone (108, 110, 112) comprises on the input end at least one protocol converter (126) for protocol conversion and coupling of a data transfer protocol that can be transmitted by means of the data diodes (120) to a data transfer protocol that can be processed by the zones (108, 110, 112) and/or on the output end comprises at least one further protocol converter (126) for protocol conversion and coupling of a data transfer protocol that can be processed by the zones (108, 110, 112) to a data transfer protocol that can be transmitted by means of the data diodes (120).
13. The device according to claim 1, characterized in that the computers are formed identically, in particular with regard to their hardware and/or operating software, and can be configured for the intended use, in particular by means of application software (122, 124), in accordance with the individual zone (108, 110, 112).
14. The device according to claim 1, characterized in that a data diode (120) is formed by a transmitting unit (128), which is part of a respective zone (108, 110, 112), and a receiver unit (136), which is part of a zone (110, 112) having a lower level of data security, wherein a data transmission means (138) is used to interconnect the transmitting unit (128) and the receiver unit (136).
15. The device according to claim 1, characterized in that the transmitting unit (128) is formed as a transmitting data diode comprising a laser diode (134), and, in particular, a multiplexer (130) and a modulator (132), in that the receiver unit (136) is formed as a receiving data diode comprising a photo diode (142) and in particular a demodulator (144) and a demultiplexer (146), and in that the transmitting unit (128) and the receiver unit (136) are interconnected via the data transmission means (138) in the form of an optical fiber cable (140).
16. A manufacturing machine having a device according to claim 1 as an integral part thereof.
17. A production plant comprising a plurality of manufacturing machines according to claim 16.
Type: Application
Filed: Aug 27, 2019
Publication Date: Jun 17, 2021
Patent Grant number: 11689540
Inventors: Gert HANSEN (Gaggenau), Helmut JACOB (Ettlingen)
Application Number: 17/270,145